H42 Transmission, Tcase, eBrake Rebuild in a '76 FJ40` (1 Viewer)

[Weber Sarge]

LOL - I would certainly hope so anyway .
Sarge

 

[Vae Victus]

Yes, the front bolts are all the same length. The tower bolts and frt cover bolts are mixed up. Might also be some of the bolts for the T-case PTO sidecover.

I'm going to have to sort that out - 3 bolts were 30mm in the front bearing retainer, and the rest were 25mm. All the ones in the top cover were - hmmm, I forgot what they were, but they were all the same. Perhaps that's where the long ones go. Pics would help. Mine were bagged as I removed them so I didn't mix them up.

 

[Vae Victus]

On MLK day, I played hooky with the kids and married the tranny and transfer case.


Gasket (sealant used, RTV on the tranny side, and spray on to the t-case side.

Slid the gear and spacer onto the output shaft as I slid the t-case into position. I simply put both cases in the floor in order to marry them. Put a 1" board under the t-case to elevate it a bit to match up. Went on easily. Even was available to put the gear and spacer on by myself the first (or second) try. Make sure the gear is turned the right way. The long nose goes toward the tranny.


Gear and spacer



Torqued the bolts to 50 ft lbs.

Then attached the PTO cover to the t-case. Used RTV on the gasket here for a good seal. (Purists look away!)


Gasket

Last was the bearing for the output shaft. I put it in the freezer for a while to contract it a bit. Then tapped it on with a brass drift around the inner race. Seated it on the spacer. I guess that's the right distance? I test fit it and it would simply slide thru the hole in the case without the output shaft and spacer to stop it.





Next is the retaining nut and washers for the output shaft, and the same for the parking brake shaft, plus the brake itself. I'm in San Antonio for business right now, and it's 5 degrees at home, so it'll be a while.

 

[Vae Victus]

Oh, and as a bonus, I learned a trick from Rainman that I thought I'd share. Removing the shifter from the case top.

All you have to do is stick a pair of needle nose pliers in the top of the shift cover as shown in the photo, push down, and twist [EDIT] clockwise about 1/8th of a turn. Pops right out. You have to catch the corners of the outer metal shield - that's what twists. If you are careful, it won't scratch the mechanism.


Pliers in position


Twist and lift


Clean off the components


Line up for reinsertion


Put the slots on the guides and twist [EDIT] CCW to reinsert

 

[FJ40Jim]

If that is a trick for removing shifter, what is the not-tricky way to remove shifter?
How did you remove it before?

I'm unaware of an alternative method.

 

[subzali]

From the picture, it looks like twist right to remove and left to re insert? I've heard that it could be either way (different part was used) with no rhyme or reason to indicate which Sent from my iPhone using IH8MUD at 85mph in an FJ40

 

[Pin_Head]

I think the 3sp and GM trannys twist CCW to remove.

Twist the night away.

 

[Vae Victus]

If that is a trick for removing shifter, what is the not-tricky way to remove shifter?
How did you remove it before?

I'm unaware of an alternative method.

HA! Well I've only seen the FSM way with the special tool, so this tip from Rainman was very helpful. Though I'd share in case others weren't familiar.

 

[Vae Victus]

From the picture, it looks like twist right to remove and left to re insert? I've heard that it could be either way (different part was used) with no rhyme or reason to indicate which Sent from my iPhone using IH8MUD at 85mph in an FJ40

Yep - had it backwards. Fixed.

 

[Vae Victus]

Crap - I did this backwards didn't I? I put the long spacer inside, and have the short one outside. Bearing goes in a bit, but the washers and the nut don't snug up against the spacer. In my pictures, I see that the spacer was longer on the shaft before the Nut and washers (I think).


Without spacer. Note bearing depth



With spacer. Clearly not right.

Did I swap them?

EDIT: photo from early in the rebuild:


This is the spacer pictured above. Clearly in the wrong spot currently. This photo shows it on the output shaft prior to tcase.

EDITED TO MATCH FJ40Jim's CORRECTIONS BELOW:
Output shaft area needs to be in this order:
- Tranny
- Tranny output bearing
- Output shaft spacer (the one just above)
- transfer case
- inside the transfer case - T-case drive gear,
- inside transfer case, PTO gear or spacer
- output shaft t-case bearing
- yet another spacer or rear PTO drive
- washers and nut
- Tail cone

Is this right?

 

[FJ40Jim]

Output shaft area needs to be in this order:
- Tranny
- Tranny output bearing
- Output shaft short spacer (the one just above)
- transfer case
- inside the transfer case - T-case drive gear,
- inside transfer case, spacer or PTO gear
- output shaft tcase bearing
- yet another spacer or rear PTO drive
- washers and nut
- tail cone

Is this right?

It's right now.

 

[Vae Victus]

From your post above Jim, it appears I'm missing a spacer - the inner one with the T-case drive gear, or the outer one between the bearing and the nut.

Here's what my inside spacing looks like.

 

[Vae Victus]

Which order do the spacers go? I didn't take good photos of these.

The three spacers are the following lengths.


Short one by tranny ~ 25mm


Second one ~ 45mm


~ 40mm (best I can tell since its installed in the t-case)

 

[FJ40Jim]

The t-case has to come off, so pull it off and see which spacer goes where. You can determine for sure by measuring inside case w/ T-case main drive gear is in place, the distance from back of gear to front of rear t-case bearing. Front face of rear t-case bearing should be about flush w/ inside of case. Pics in post #210 look like rear t-case bearing could be driven a little farther forward into t-case.

 

[Pin_Head]

The spacer on the tranny side of the transfer input gear may be too short because it doesn't look like the gears mesh properly (unless this is an optical illusion).

 

[hotpoker01]

VV in response to your request on my thread - does this help?


Top of photo is top of PTO window





Although the transfer case looks different in some respects (look at he webbing pattern, and no internal bolts that i can see)? I think I have a H42.

 

[hotpoker01]

duplicate

 

[nickolai]

VV in response to your request on my thread - does this help? Top of photo is top of PTO window Although the transfer case looks different in some respects (look at he webbing pattern, and no internal bolts that i can see)? I think I have a H42.

Same gearbox, but Different cases though hot poker - VV's is a "one piece" and your case is a "split case". This probably makes a difference - though I'm not certain- I've only messed with one pieces. Someone smarter than I will know for sure...

 

[HoffLarr]

Great thread and great info; I've read through the whole thing from the beginning. I have a pic that may help you.

I've taken off the PTO cover on my 77 with H42 to see if it had the PTO gear (no such luck) but as you can see, the spacer goes right out the edge of the case, so I am guessing, the 45mm spacer is probably the one that goes inside...maybe.



As far as I know this case has never been rebuilt.

Hope this helps. Thanks for all the great info with pics.

 

[FJ40Jim]

Hotpoker's pics, while very good quality, are of a different setup and may be confusing.

Hofflar's pic show how the main drive gear and idler gear should line up just about perfect.
Also visible is how the rearmost bearing ends up flush w/ the inside of the case.